Thermal protector

ABSTRACT

A thermal protector has superiority in current responsiveness or thermal responsiveness with a simple configuration that does not need a separate manufacturing step of incorporating a resistor. At a stage of press processing for cutting from an original material, a movable plate body part  16  of a movable plate  4  is partitioned into a narrow-width part  17  and a wide-width part  18  by a slim hole  19.  The movable plate  4  is assembled to a fixed conductor  2  with columns  9  of an insulator  3,  a bimetal  5  is assembled to the movable plate  4,  the entire configuration is pressed down by a resinous block  6,  and the entire fixing part is fixed by melting tips of the columns  9.  The wide-width part  18  serves as a normal movable plate, whereas the narrow-width part  17  serves as a conductor in a normal state and as a resistor against an overcurrent.

TECHNICAL FIELD

The present invention relates to a thermal protector having superiorityin electric current responsiveness or thermal responsiveness with asimple configuration that does not need a separate manufacturing step ofincorporating a resistor.

BACKGROUND ART

Thermal protectors that open/close a contact by inverting and driving abimetal with Joule heat produced by an applied current are known asconventional techniques.

Most of these thermal protectors incorporate a resistor, such as a filmresistor (for example, see Patent Document 1), a metal wire resistor(for example, see Patent Document 2) or the like, for producing Jouleheat as an additional component in order to take measures in response tonot only an increase of an ambient temperature but an overcurrent.

PRIOR ART DOCUMENTS Patent Documents

Patent Document 1: U.S. Pat. No. 3,393,981

Patent Document 2: Japanese Laid-open Patent Publication No. 2003-141977

SUMMARY OF THE INVENTION Problems to be Solved by this Invention

However, the conventional techniques referred to in Patent Document 1, 2and the like have an unavoidable problem of an increase in not only theprice of a resistor as an additional component but the price of anentire thermal protector because a manufacturing step of assembling theresistor as an additional component is needed as an additional step.

Means for Solving the Problems

In order to solve the above described problem, the thermal protectoraccording to the present invention is a thermal protector foropening/closing an electric circuit with a bimetal having a warpagedirection that is inverted at a predetermined temperature in response toa change of an ambient temperature. The thermal protector includes: afixed conductor having a fixed contact provided at one end, and a firstterminal for an external connection; an insulator, provided between thefixed contact and the first terminal of the fixed conductor, havingcolumns integrally formed by being resin-molded; a movable plate havinga fixed part having holes into which the columns are inserted on theinsulator, a movable contact formed at a position facing the fixedcontact at an end on a side opposite to the fixed part, and hooks forholding the bimetal respectively on a movable end side and a fixed endside; the bimetal, held by the hooks of the movable plate, foropening/closing the movable contact and the fixed contact by invertingthe warpage direction at the predetermined temperature; and a resinousblock for fixing the fixed part to the insulator by being inserted withthe columns above the fixed part of the movable plate having the holesinto which the columns are inserted. In the thermal protector, themovable plate makes the movable contact touch the fixed contact with apredetermined spring property in a normal state, and the movable platehas a slim hole, formed by being cut from the fixed part toward themovable contact at a position closer to one of sides from a central linealong the central line that links the movable contact and the fixedpart, for partitioning the movable part into a wide-width part and anarrow-width part, and for further partitioning the fixed part up to anend consecutively to the partitioning, and a second terminal, connectedto the end consecutive to the narrow-width part of the fixed partpartitioned up to the end, for an external connection.

Additionally, to solve the above described problem, the thermalprotector according to the present invention is a thermal protector foropening/closing an electric circuit with a bimetal having a warpagedirection that is inverted at a predetermined temperature in response toa change of an ambient temperature. The thermal protector includes: afixed conductor having a fixed contact provided at one end, and a firstterminal for an external connection; an insulator, provided between thefixed contact and the first terminal of the fixed conductor, havingcolumns integrally formed by being resin-molded; a bimetal having afixed part having holes into which the columns are inserted on theinsulator, a second terminal, formed at the fixed part, for an externalconnection, a movable contact formed at a position facing the fixedcontact at an end on a side opposite to the fixed part, and an inversionoperation part, formed by being cut at a position closer to one of sidesfrom a central line along the central line that links the movablecontact and the fixed part so that the entire bimetal excluding anarrangement portion of the movable contact is partitioned into awide-width part and a narrow-width part, and formed by performingtapering processing to take an upwardly convex shape in the wide-widthpart, for performing an inversion operation at a predeterminedtemperature, the bimetal taking the upwardly convex shape in a normalstate to make the movable contact touch the fixed contact with apredetermined spring property; and a resinous block for fixing the fixedpart to the insulator by being inserted with the columns above the fixedpart of the bimetal having the holes into which the columns areinserted.

Furthermore, to solve the above described problem, the thermal protectoraccording to the present invention is a thermal protector foropening/closing an electric circuit with a bimetal having a warpagedirection that is inverted at a predetermined temperature in response toa change of an ambient temperature. The thermal protector includes: afixed conductor having a fixed contact provided at one end, and a firstterminal for an external connection; an insulator, provided between thefixed contact and the first terminal of the fixed conductor, havingcolumns integrally formed by being resin-molded; a movable plate havinga fixed part having holes into which the columns are inserted on theinsulator, a movable contact formed at a position facing the fixedcontact at an end on a side opposite to the fixed part, and hooks forholding the bimetal respectively on a movable end side and a fixed endside, the movable plate making the movable contact touch the fixedcontact with a predetermined spring property in a normal state; thebimetal, held by the hooks of the movable plate, for opening a contactbetween the movable contact and the fixed contact by inverting thewarpage direction at the predetermined temperature; and a resinous blockfor fixing the fixed part to the insulator by being inserted with thecolumns above the fixed part of the movable plate having the holes intowhich the columns are inserted. In the thermal protector, the movableplate includes a slim hole, formed by being cut from the fixed parttoward the movable contact at a position closer to one of sides from acentral line along the central line that links the movable contact andthe fixed part, for partitioning the movable plate into a wide-widthpart and a narrow-width part, and for further partitioning the fixedpart up to an end consecutively to the partitioning, a second terminalconnected to the end on the side of the fixed part consecutive to thenarrow-width part, and a third terminal connected to the end on the sideof the fixed part consecutive to the wide-width part.

Effects of the Invention

According to the present invention, at a stage of press processing forcutting a movable plate or a bimetal from an original material, anarrow-width part can be used as a resistor only by forming a slim holefor partitioning the movable plate or a bimetal body part into awide-width part and the narrow-width part. This achieves an effect suchthat a thermal protector having superiority in current responsiveness orthermal responsiveness with a simple configuration that does not need aseparate manufacturing step of incorporating a resistor can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 1 of the present invention;

FIG. 2 illustrates a state where a length of a narrow-width part isformed to be shorter, namely, approximately one half of a length of theembodiment 1 as a modification example 1 of the thermal protectoraccording to the embodiment 1 of the present invention;

FIG. 3 illustrates a state where the length of the narrow-width part isformed to be shorter, namely, approximately one quarter of the length ofthe embodiment 1 as a modification example 2 of the thermal protectoraccording to the embodiment 1 of the present invention

FIG. 4 illustrates a state where a width of the narrow-width part isformed to be narrower, namely, approximately one half of a width of theembodiment 1 as a modification example 3 of the thermal protectoraccording to the embodiment 1 of the present invention

FIG. 5 illustrates another example of a method for installing a bimetalelement as a modification example 4 of the thermal protector accordingto the embodiment 1 of the present invention;

FIG. 6 is a perspective view illustrating a structure of a movable plateof a thermal protector according to an embodiment 2 of the presentinvention;

FIG. 7 is a perspective view illustrating a structure of an insulator asa modification example of the thermal protector according to theembodiment 2 of the present invention;

FIG. 8 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 3 of the present invention;and

FIG. 9 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 4 of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments according to the present invention are described in detailbelow.

Embodiment 1

FIG. 1 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 1. As illustrated in FIG.1, the thermal protector 1 according to this embodiment includes a fixedconductor 2, an insulator 3, a movable plate 4, a bimetal 5 and aresinous block 6.

The fixed conductor 2 has a fixed contact 7 provided at one end, and afirst terminal 8, connected to an end opposite to the end provided withthe fixed contact 7, for an external connection.

The insulator 3 is provided by being resin-molded between the fixedcontact 7 and the first terminal 8 of the fixed conductor 2. Theinsulator 3 has two columns that are integrally formed by beingresin-molded.

The movable plate 4 has a fixed part 12 having holes 11 into which thecolumns 9 are inserted on the insulator 3, a movable contact 13 formedat a position facing the fixed contact 7 of the fixed conductor 2 at anend on a side opposite to the fixed part 12, and one hook 14 and twohooks 15, which respectively hold the bimetal 5 on a movable end sideprovided with the movable contact 13 and a fixed end side provided withthe fixed part 12.

Additionally, a slim hole 19, formed by being cut from the fixed part 12toward the movable contact 13 at a position closer to one (the upwardlyleft direction in FIG. 1) of sides from a central line along the centralline that links the movable contact 13 and the fixed part 12, forpartitioning a movable plate body part 16 into a narrow-width part 17and a wide-width part 18 is provided on the movable plate 4.

The slim hole 19 further partitions the fixed part 12 almost at a centerup to the end consecutive to the above described partitionednarrow-width part 17 and wide-width part 18. To the movable plate 4, asecond terminal 21 for an external connection is connected to the endconsecutive to the narrow-width part 17 of the fixed part 12 partitionedup to the end. Moreover, on the wide-width part 18, a protrusion 20 isformed at a portion that touches almost the center of the movable plate16.

The bimetal 5 is formed by drawing compound processing so that a centralpart 22 takes an upwardly convex shape at a normal temperature asillustrated in FIG. 1, and its warpage direction is inverted so that thecentral part 22 takes the upwardly concave shape at a predeterminedtemperature higher than the normal temperature.

The resinous block 6 has penetration holes 23 into which the columns 9of the insulator 3 are inserted, and a level difference part 24 thatserves as an escape part from the hooks 15 on the side of the fixed endof the movable plate 4 upon completion of the entire assembly is formedat a bottom.

To assemble the components illustrated in FIG. 1, the movable plate 4 isinitially assembled to the fixed conductor 2 where the central part isinsulated with the insulator 3 by inserting the columns 9 of theinsulator 3 into the holes 11 of the fixed part 12 of the movable plate4.

Next, the bimetal 5 is assembled to the movable plate 4 by engaging bothends (the end in the lower left direction and the end in the upper rightdirection in FIG. 1) of the bimetal 5 with the one hook 14 and the twohooks 15 of the movable plate 4.

Then, the fixed part 12 of the movable plate 4 is fixed to the insulator3 by being pressed by the resinous block 6 with an insertion of thecolumns 9 of the insulator 3 into the penetration holes 23 of theresinous block 6, and tips of the columns 9 made of resin are melted topress down the resinous block 6 with the columns 9, so that the resinousblock 6 is fixed to the insulator 3.

The assembly is completed in this way. In this state, namely, in thenormal state, the movable contact 13 of the movable plate 4 touches thefixed contact 7 of the fixed conductor 2 with a predetermined pressureby means of a spring property possessed by the wide-width part 18 of themovable plate body part 16. The spring property possessed by thewide-width part 18 is set so that the contact pressure generated at thistime is, for example, 98 mN (milli Newton).

Additionally, the bimetal 5 warps in the upwardly convex state in thenormal state (at a normal temperature) as described above (asillustrated in FIG. 1), and its central part slightly touches theprotrusion 20 of the movable plate 4. Moreover, the bimetal 5 invertsits warpage direction to an upwardly concave shape in response to achange of an ambient temperature to an inversion operation temperaturespecific to the bimetal 5 or higher.

The ambient temperature rises because the narrow-width part 17 of themovable plate 4 is arranged in an electric circuit formed between thefirst terminal 8 and the second terminal 21 via the movable contact 13and the fixed contact 7, and the narrow-width part 17 operates as aresistor when a current is applied to a long portion having a smallcross-section of the narrow-width part 17.

Namely, the narrow-width part 17 serves as both a conductor and theresistor when power is applied. Moreover, the narrow-width part 17operates as the resistor when an applied current becomes an overcurrent,so that Joule heat equal to or higher than the inversion operationtemperature specific to the bimetal 5 is generated. As a result, thebimetal 5 is inverted.

With the above described inversion of the bimetal 5, the bimetal 5 liftsup the side of the end provided with the one hook 14, namely, the endprovided with the movable contact 13 of the movable plate 4 according tothe principle of leverage that uses the protrusion 20 and the two hooks15 respectively as a fulcrum and pressing portions. As a result, thecontact between the movable contact 13 and the fixed contact 7 isopened, whereby power applied to the electric circuit formed between thefirst terminal 8 and the second terminal 21 is interrupted.

Selecting a material having a low conductivity, such as stainless steel,as a material of the above described movable plate 4 is effective forthe narrow-width part 17 that operates as the resistor. Assuming that alength c of the narrow-width part 17 along the slim hole 19 illustratedin FIG. 1 is approximately 9 mm, a thickness of the movable plate 4 is0.1 mm, and a width a of the narrow-width part 17 is 0.5 mm, aresistance value of approximately 0.2Ω is obtained with a measuringinstrument.

A resistance of a conventional copper spring material without the slimhole 19 (namely, a movable plate without the narrow-width part 17) isseveral mΩ. By configuring the movable plate 4 in the form of theembodiment 1 illustrated in FIG. 1, it is proved that a resistance valueof nearly 100 times a conventional value can be set.

Additionally, with a conventionally studied method for thinning thethickness of a movable plate, the resistance value does not increaseseveralfold, and at the same time, a function as a spring is damaged.Therefore, the conventional method could not be actually employed.

With the method for configuring the movable plate in the form of theembodiment 1 according to the present invention, the wide-width part 18partitioned by the slim hole 19 has a sufficient thickness. Therefore,the wide-width part 18 can be sufficiently used as a spring. Moreover,the spring property is not deteriorated by overheat because a current isnot applied to the wide-width part 18. Therefore, a thermal protectorhaving a high resistance can be provided while maintaining performanceas a switch.

It is said that the above described function as a spring is normallysufficient as a silver contact if the contact pressure is equal to orhigher than 98 mN, and the contact pressure can be also adjusted with awidth partitioned by the slim hole.

Namely, if a ratio “a:b” of the width a of the narrow-width part 17 tothe width b of the wide-width part 18, which are partitioned by the slimhole 19, is equal to or larger than “1:2” (namely, “a/b”≦“½”) althoughit depends on the thickness of the movable plate, it is proved as aresult of various experiments that the spring property of the wide-widthpart 18 that operates as a spring is not affected by the narrow-widthpart 18 that operates as a resistor and the wide-width part 18 canstably operate as a spring.

If the ratio of the width a of the narrow-width part 17 to the width bof the wide-width part 18 is set to “1:1”, also the spring property ofthe narrow-width part 17 that operates as the resistor is strengthened.However, the narrow-width part 17 that operates as the resistor issignificantly deteriorated, leading to a possibility that the entireproperty change exceeds a tolerable range. Accordingly, it is preferableto set “a/b”≦“½”.

As described above, according to the embodiment 1, a high internalresistance can be set in the same configuration as a conventionalcomponent, and the internal resistance is not incorporated as anadditional component in the thermal protector. This achieves anadvantage of suppressing processing cost.

Additionally, the resistor produces heat in the neighborhood of thebimetal compared with the conventional form of adding a resistor to athermal protector. Therefore, a thermal protector having high thermalresponsiveness of the bimetal, namely, a thermal protector having highthermal responsiveness is realized.

Furthermore, even in the form of arranging the resistor part in the samecomponent as described above, the spring part (wide-width part) and theresistor part (narrow-width part) are physically partitioned by the slimhole, and a current is not applied to the spring part. This can minimizethe deterioration of the spring property, whereby a highly reliablethermal protector can be obtained.

Setting of an association between the above described inversionoperation temperature specific to the bimetal 5 and the narrow-widthpart 17 that produces Joule heat equal to or higher than the inversionoperation temperature can be adjusted by initially increasing/decreasinga length c from the fixed part 12 of the narrow-width part 17 to themovable contact 13 in FIG. 1.

FIG. 2 illustrates a modification example 1 of the embodiment 1, andillustrates a state where the length of the narrow-width part 17 isformed to be shorter than the length c of FIG. 1, namely, a length d ofapproximately one half. If the length of the narrow-width part 17 of themovable plate 4 is set to ½ in this way, Joule heat drops to one halfwith a simple calculation compared with the case of the original lengthillustrated in FIG. 1. As a result, a higher current can be applied tothe thermal protector 1.

FIG. 3 illustrates a modification example 2 of the embodiment 1, andillustrates a state where the length of the narrow-width part 17 isformed to be shorter than the length c of FIG. 1, namely, a length e ofapproximately one quarter. If the length of the narrow-width part 17 ofthe movable plate 4 is set to be one quarter as described above, Jouleheat drops to one quarter with a simple calculation compared with thecase of the original length illustrated in FIG. 1. As a result, a highercurrent can be applied to the thermal protector 1.

FIG. 4 illustrates a modification example of the embodiment 1, andillustrates a state where the width of the narrow-width part 17 isformed to be narrower than the width a of FIG. 1, namely, a width f ofapproximately one half. If the width of the narrow-width part 17 of themovable plate 4 is set to one half in this way, Joule heat is doubledwith a simple calculation compared with the case of the original widthillustrated in FIG. 1. As a result, a current can be interrupted with alower overcurrent.

Additionally, if the width of the narrow-width part is narrowed asdescribed above, a temperature of the narrow-width part 17 as a resistorbecomes very high when an overcurrent of, for example, ten times a ratedcurrent is applied. In this case, the narrow-width part 17 interruptsapplied power by melting itself with its Joule heat before the contactis opened by the inversion of the bimetal 5. The thermal protector canbe configured also in this way.

FIG. 5 illustrates a modification example 4 of the embodiment 1, namely,another example of the method for installing the bimetal 5. The samecomponents in FIG. 5 as those of the configuration illustrated in FIG. 1or 4 are denoted with the same reference numerals as those of FIG. 1 or4.

As illustrated in FIG. 5, in the modification example 4, the movableplate 4 has only the hook 14 formed on the movable end side, namely, atthe end provided with the movable contact 13, and the two hooks 15provided on the side of the fixed part in the embodiment 1 of FIG. 1 areremoved.

The bimetal 5 has a fixed part 26 where holes 25, into which the columns9 of the fixed conductor 2 are inserted, are formed at the end on thefixed side as a replacement for the removed two hooks 15.

For the bimetal 5 according to this embodiment, its end (the end in thelower left direction of FIG. 5) that moves when the bimetal 5 isinverted in the warpage direction is held by the hook 14, and the fixedpart 26 is fixed to the fixed part 12 of the movable plate 4 by theresinous block 6 via an insulation sheet 27 (where holes 28 into whichthe columns 9 of the fixed conductor 2 are inserted) newly provided inthis embodiment. Operations performed for an overcurrent are similar tothose of the embodiment 1.

Embodiment 2

FIG. 6 is a perspective view illustrating a structure of a movable plateof a thermal protector according to an embodiment 2 of the presentinvention. FIG. 6 also illustrates, above the movable plate 4, a bimetal5 that operates according to the structure of the movable plate 4.

On the movable plate 4 in this embodiment, a protrusion 29 higher by onelevel is provided in a portion closer to the narrow-width part 27 at theroot on the side of the wide-width part 18. If the protrusion 29 iscloser to the side of the narrow-width part 17 as described above, apoint 31 closer to the narrow-width part 17 from the middle of the endon the fixed side of the bimetal 5 touches the protrusion 29 when theend on the fixed side of the bimetal 5 engages with the hooks 15 on thefixed side of the movable plate 4.

As a result, the end on the fixed side of the bimetal 5 tilts to theside of the wide-width part 18 as indicated by arrows g and h in termsof balance with respect to the protrusion 29 as a fulcrum of a seesaw.Accordingly, the end on the fixed side of the bimetal 5 can be preventedfrom touching the narrow-width part 17.

This can overcome the problem of disabling the function of thenarrow-width part 17 as a resistor due to short-circuiting of theseparated fixed part 12 of the movable plate 4.

FIG. 7 is a perspective view illustrating a structure of an insulator asa modification example of the thermal protector according to theembodiment 2 of the present invention. The insulator 3 in thisembodiment has a protrusion 32 at a position slightly closer to thenarrow-width part 17 of the movable plate 4 from a central line in frontof the columns 9.

After all the components are assembled, this protrusion 32 protrudes ata position corresponding to a line that links the hooks 15 respectivelyprovided on both sides of the fixed end side of the movable plate 4through the slim hole 19 (strictly, a long hole partitioning into thewide-width part 18 and the narrow-width part 17, and a consecutiveportion 19 a of a long hole that is consecutive to the long hole andpartitions the fixed part 12 up to the end) that partitions the movableplate 4 into the wide-width part 18 and the narrow-width part 17.

Also in this case, the protrusion 32 that protrudes through the uppersurface of the fixed part side of the movable plate 4 is closer to theside of the narrow-width part 17. Therefore, the point 31 closer to thenarrow-width part 17 from the middle of the end on the fixed side of thebimetal 5 touches the protrusion 32 when the end on the fixed side ofthe bimetal 5 is engaged with the hooks 15 on the fixed side of themovable plate 4.

As a result, the end on the fixed side of the bimetal 5 tilts to theside of the wide-width part 18 as indicated by arrows g and h in termsof balance with respect to the protrusion 32 as a fulcrum of a seesaw.Accordingly, the end on the fixed side of the bimetal 5 can be preventedfrom touching the narrow-width part 17.

Note that similar effects can be achieved also by configuring themovable plate 4 to lower the top and the bottom positions of thenarrow-width part 17 with bending processing performed for the hooks ofthe movable plate 4 toward the side of the movable contact 13 of thenarrow-width part 17 when the hooks of the movable plate 4 are bended,although this is not illustrated.

Additionally, in both the embodiment 2 and its modification example,operations for interrupting a current against an overcurrent are similarto those of the embodiment 1. As described above, according to theembodiment 2 and its modification example, the end on the fixed side ofthe bimetal can prevent the narrow-width part as a resistor part and thewide-width part as a spring part from being short-circuited at the fixedpart, whereby a stable characteristic as a thermal protector can beachieved.

Embodiment 3

FIG. 8 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 3 of the present invention.The same components in FIG. 8 as those of FIG. 1 are denoted with thesame reference numerals as those of FIG. 1. As illustrated in FIG. 8, inthe thermal protector 30 in this embodiment, configurations of a fixedconductor 2, an insulator 3 and a resinous block 6 are the same as thoseof FIG. 1.

In the thermal protector according to this embodiment, the movable plate4 of FIG. 1 is removed, and a bimetal 33 serves as a movable plate, aresistor and a bimetal. Namely, the thermal protector 30 according tothis embodiment is an example of a structure for directly applying acurrent to the bimetal.

The bimetal 33 in this embodiment has a fixed part 35 having holes 34into which the columns 9 are inserted on the insulator 3. The bimetal 33also has a second terminal 21, formed at the fixed part 35, for anexternal connection, and a movable contact 13 formed at a positionfacing the fixed contact 7 of the fixed conductor 2 at the end on asideopposite to the fixed part 35.

Additionally, in the whole of the bimetal 33 excluding the arrangementportion of the movable contact 13, a slim hole 36 is formed at aposition closer to one (in the upper left direction in FIG. 8) of thesides from a central line along the central line that links the movablecontact 13 and the fixed part 35. By the slim hole 36, the bimetal 33 ispartitioned into a narrow-width part 37 and a wide-width part 38excluding the arrangement portion of the movable contact 13.

Additionally, the narrow-width part 37 is configured to serve as aconductor part in an electric circuit applied between the first terminal8 and the second terminal 21 via the fixed contact 7 and the movablecontact 13 in a normal state, and to serve as a resistor part forproducing desired Joule heat when an applied current becomes anovercurrent of a predetermined value or larger. Since the bimetal itselfis made of a material originally having a low conductivity, it ispreferable to obtain a high resistance with the narrow-width part 37.

In the meantime, the wide-width part 38 configures an inversionoperation part, formed by performing drawing compound processing 39 totake an upwardly convex shape, for performing an inversion operation ata predetermined temperature (temperature corresponding to the abovedescribed desired Joule heat). This wide-width part 38 serves as both abimetal and a movable plate, takes the upwardly convex shape in a normalstate, and makes the movable contact 13 touch the fixed contact 7 with apredetermined spring property. Note that operations for interrupting acurrent against an overcurrent are similar to those of the embodiment 1.

Embodiment 4

FIG. 9 is an exploded perspective view illustrating a structure of athermal protector according to an embodiment 4 of the present invention.The same components in FIG. 9 as those of FIG. 1 are denoted with thesame reference numerals as those of FIG. 1. As illustrated in FIG. 9,configurations of a fixed conductor 2, an insulator 3, a bimetal 5 and aresinous block 6 are the same as those of FIG. 1 in the thermalprotector 40 according to this embodiment.

Unlike the thermal protector 1 according to the embodiment 1 illustratedin FIG. 1, a new terminal is connected as a third terminal 41 to thefixed part 12 of the wide-width part 18 as well as the fixed part 12 ofthe narrow-width part 17 partitioned by the slim hole 19 of the movableplate 4 in the thermal protector 40 according to this embodiment.

A relationship between the third terminal 41 and the first terminal 8 ofthe fixed conductor 2, which are connected via the wide-width part 18,can be considered as being identical to the basic structure ofconventional thermal protector terminals.

In contrast, with a relationship between the first terminal 8 and thesecond terminal 21, which are connected via the narrow-width part 27, anapplied current produces more heat since the narrow-width part 17 as aresistor is provided in between.

A usage example of this thermal protector 40 is as follows. If aheat-resistance limit of an operating temperature of a normal thermalprotector varies depending on a usage environment, measures can betaken, for example, against a temperature of heat produced by anoverloaded battery.

Namely, a charging side has an unadjustable structure for the case whereheat is produced by an overcharged battery. Therefore, differentmeasures can be set such that the third terminal for an externalconnection is connected to the side of the wide-width part 18, and anoperating temperature of the thermal protector is reduced below apredetermined temperature with a current applied to the terminal on theside of the narrow-width part 17, and the thermal protector is operatedat a lower temperature.

These settings can be adjusted, for example, by varying the lengthpartitioned by the slim hole, or the width of the narrow-width partpartitioned by the slim hole in a similar manner as in the modificationexamples 1, 2 and 3 of the embodiment 1.

INDUSTRIAL APPLICABILITY

The present invention is applicable to a thermal protector havingsuperiority in current responsiveness or thermal responsiveness with asimple configuration.

EXPLANATION OF CODES

-   1 thermal protector-   2 fixed conductor-   3 insulator-   4 movable plate-   5 bimetal element-   6 resinous block-   7 fixed contact-   8 first terminal-   9 columns-   11 holes-   12 fixed part-   13 movable contact-   14, 15 hooks-   16 movable plate body part-   17 narrow-width part-   18 wide-width part-   19 slim hole-   19 a slim hole consecutive part-   20 protrusion-   21 second terminal-   22 central part-   23 penetration hole-   24 level difference part-   25 holes-   26 fixed part-   27 insulation sheet-   28 holes-   29 protrusion-   30 thermal protector-   31 point closer to narrow-width part-   32 protrusion-   33 bimetal-   34 holes-   35 fixed part-   36 slim hole-   37 narrow-width part-   38 wide-width part-   39 tapering processing-   40 thermal protector-   41 third terminal

1. A thermal protector for opening/closing an electric circuit with abimetal having a warpage direction that is inverted at a predeterminedtemperature in response to a change of an ambient temperature,comprising: a fixed conductor having a fixed contact provided at oneend, and a first terminal for an external connection; an insulator,provided between the fixed contact and the first terminal of the fixedconductor, having columns integrally formed by being resin-molded; amovable plate having a fixed part having holes into which the columnsare inserted on the insulator, a movable contact formed at a positionfacing the fixed contact at an end on a side opposite to the fixed part,and hooks for holding the bimetal respectively on a movable end side anda fixed end side; the bimetal, held by the hooks of the movable plate,for opening/closing a contact between the movable contact and the fixedcontact by inverting the warpage direction at the predeterminedtemperature; and a resinous block for fixing the fixed part to theinsulator by being inserted with the columns above the fixed part of themovable plate having the holes into which the columns are inserted,wherein the movable plate makes the movable contact touch the fixedcontact with a predetermined spring property in a normal state, and themovable plate comprises a slim hole, formed by being cut from the fixedpart toward the movable contact at a position closer to one of sidesfrom a central line along the central line that links the movablecontact and the fixed part, for partitioning the movable part into awide-width part and a narrow-width part, and for further partitioningthe fixed part up to an end consecutively to the partitioning, and asecond terminal, connected to the end consecutive to the narrow-widthpart of the fixed part partitioned up to the end, for an externalconnection.
 2. The thermal protector according to claim 1, wherein thepredetermined spring property is a spring property, given to thewide-width part, for generating a contact pressure set to at least 98 mN(milli Newton), and the narrow-width part is used as both a conductorand a resistor when power is applied to the contact.
 3. The thermalprotector according to claim 1, wherein a width a of the narrow-widthpart and a width b of the wide-width part have a relationship of“a/b≦“½”.
 4. The thermal protector according to claim 1, wherein thenarrow-width part is formed by being cut to have a thickness and alength, which are melted by Joule heat corresponding to an overcurrentwhen the predetermined overcurrent or higher is applied to the contact.5. The thermal protector according to claim 1, wherein the movable platehas the hook only on the movable end side, the bimetal has an end thatmoves when the bimetal is inverted in the warpage direction and is heldby the hook, and has a fixed part having holes into which the columnsare inserted on the fixed end side, and the fixed part is fixed to thefixed part of the movable plate by the resinous block via an insulationsheet.
 6. The thermal protector according to claim 1, wherein themovable plate has a convex part for preventing a side end part of thebimetal facing the narrow-width part from touching the narrow-width partby lifting up the bimetal with respect to the hook on the side of thewide-width part as a fulcrum when the bimetal is engaged with the hookson both sides at a position that corresponds to a line linking the hooksrespectively provided on the both sides of the fixed end side and isclosest to the side of the narrow-width part in the wide-width part. 7.The thermal protector according to claim 1, wherein the insulator has aconvex part that protrudes at a position corresponding to a line linkingthe hooks respectively provided on both sides of the fixed end side ofthe movable plate through the slim hole that partitions the movableplate into the wide-width part and the narrow-width part, and prevents aside end part of the bimetal facing the narrow-width part from touchingthe narrow-width part by lifting up the bimetal with respect to the hookon the side of the wide-width part as a fulcrum when the bimetal isengaged with the hooks on the both sides.
 8. A thermal protector foropening/closing an electric circuit with a bimetal having a warpagedirection that is inverted at a predetermined temperature in response toa change of an ambient temperature, comprising: a fixed conductor havinga fixed contact provided at one end, and a first terminal for anexternal connection; an insulator, provided between the fixed contactand the first terminal of the fixed conductor, having columns integrallyformed by being resin-molded; a bimetal comprising a fixed part havingholes into which the columns are inserted on the insulator, a secondterminal, formed at the fixed part, for an external connection, amovable contact formed at a position facing the fixed contact at an endon a side opposite to the fixed part, and an inversion operation part,formed by being cut at a position closer to one of sides from a centralline along the central line that links the movable contact and the fixedpart so that the entire bimetal excluding an arrangement portion of themovable contact is partitioned into a wide-width part and a narrow-widthpart, and formed by performing tapering processing to take an upwardlyconvex shape in the wide-width part, for performing an inversionoperation at a predetermined temperature, the bimetal taking theupwardly convex shape in a normal state to make the movable contacttouch the fixed contact with a predetermined spring property; and aresinous block for fixing the fixed part to the insulator by beinginserted with the columns above the fixed part of the bimetal having theholes into which the columns are inserted.
 9. The thermal protectoraccording to claim 8, wherein the narrow-width part is used as both aconductor and a resistor when power is applied to the contact.
 10. Athermal protector for opening/closing an electric circuit with a bimetalhaving a warpage direction that is inverted at a predeterminedtemperature in response to a change of an ambient temperature,comprising: a fixed conductor having a fixed contact provided at oneend, and a first terminal for an external connection; an insulator,provided between the fixed contact and the first terminal of the fixedconductor, having columns integrally formed by being resin-molded; amovable plate having a fixed part having holes into which the columnsare inserted on the insulator, a movable contact formed at a positionfacing the fixed contact at an end on a side opposite to the fixed part,and hooks for holding the bimetal respectively on a movable end side anda fixed end side, the movable plate making the movable contact touch thefixed contact with a predetermined spring property in a normal state;the bimetal, held by the hooks of the movable plate, for opening acontact between the movable contact and the fixed contact by invertingthe warpage direction at the predetermined temperature; and a resinousblock for fixing the fixed part to the insulator by being inserted withthe columns above the fixed part of the movable plate having the holesinto which the columns are inserted, wherein the movable plate comprisesa slim hole, formed by being cut from the fixed part toward the movablecontact at a position closer to one of sides from a central line alongthe central line that links the movable contact and the fixed part, forpartitioning the movable plate into a wide-width part and a narrow-widthpart, and for further partitioning the fixed part up to an endconsecutively to the partitioning, a second terminal connected to theend on the side of the fixed part consecutive to the narrow-width part,and a third terminal connected to the end on the side of the fixed partconsecutive to the wide-width part.
 11. The thermal protector accordingto claim 10, wherein the first terminal is connected to a power supplyside, the third terminal is connected to a load side, and the bimetal isheated with Joule heat of the narrow-width part by applying powerbetween the second terminal and the first terminal, so that the bimetalperforms an inversion operation at a temperature equal to or lower thanan inversion operation temperature specific to the bimetal.